Sector News
New bearing solutions for higher power density, longer operating times, and lower carbon footprint
At any given moment during the day, 2,000 thunderstorms are active around the world. That amounts to sixteen million of such severe weather events per year. With wind turbines stretching up to a couple hundred meters above ground, very often in flat areas with no other big structures nearby, they are easy targets for lightnings. Some estimate that every blade will be struck, on average, 128 times over a period of 20 years, potentially causing important economic damage.
Wind turbine manufacturers and operators are currently faced with enormouschallenges. How can higher performance be delivered on a permanent basis withinexactly the same installation space while simultaneously extending the lifetimes ofexisting wind farms, improving the carbon footprint, and ultimately reducing electricitygeneration costs? Schaeffler provides answers to these questions at WindEnergyHamburg from September 27-30, 2022. In Hall B5, Booth 333, visitors will beable to discover the innovative solutions being offered by the company and theresulting possibilities for producing wind turbines, and operating them sustainably andeconomically.
Series-ready hydro-dynamic plain bearings for planetary gears
Increasing power density in wind turbine gears, combined with the demand for reducedweight and cost, requires new bearings concepts. With planetary gears, this leads toa larger number of planets with smaller diameters, known as ‘multi-planet concepts.’This means that not enough space is available for rolling bearings in the planet gears.Hydro-dynamic plain bearings are the solution here because of their low cross-section. At WindEnergy Hamburg, Schaeffler is introducing its new hydro-dynamic plain bearingsand related engineering for planet gears. This is because a thorough understanding ofthe systems and new simulation and calculation methods, as well as the correspondingtools, is required to ensure that the bearings function smoothly.
Adjusted rotor bearings: compact and safe operation with PREMESY
Performance optimization has brought about a marked trend towards adjusted bearingswith two tapered roller bearings in an O arrangement. The increased support spacing ofthis bearing arrangement reduces the inner bearing loads, whereby the bearing can bemade smaller and lighter. To ensure that the adjusted bearings continue to function yearon year, Schaeffler engineers fall back on various options from the tapered roller bearingconstruction kit. Selection takes place as part of a multi-level system simulation, whichtakes into account the effect of forces and deformation on the bearings in operation. Thebearing details are checked, and in a simulation, the correct pre-load – essential for theadjusted bearings – is determined. In order to ensure this, both during the installationprocess and in operation, Schaeffler offers the PREMESY pre-load measuring system.
Split asymmetric spherical roller bearings: economical operation after a changeof bearings
Worldwide, a large proportion of the drive train concepts installed on rotors are fittedwith spherical roller bearings. If these bearings fail prematurely, the high replacementcost, e.g., for cranes, usually renders it uneconomical to replace them. For such cases, Schaeffler has developed a robust and innovative solution based on split asymmetricspherical roller bearings. This solution can reduce the cost of replacing the bearings by agood 50 percent. Since the entire replacement process takes place in the nacelle, it is notnecessary to disassemble the rotor star or powertrain. All the necessary components arelifted into the nacelle using the deck crane and assembled in situ. Therefore, Schaefflerenables operators to continue to operate existing wind turbines cost-effectively.
CO2 footprint: major progress possible in the manufacture of rolling bearings
Wind energy is second only to hydroelectric power as one of the most climate-friendlyenergy production technologies. However, emissions in the upstream chain are alsoconsidered, such as in the production and processing of steel to manufacture the variouscomponents of a wind turbine. In order to significantly reduce the carbon footprint of rollerbearings, Schaeffler implements CO2 savings potentials across the entire value chain, from the procurement of the steel, through the manufacturing process, to the logisticsand packing.
Strategic partner for the energy revolution with green hydrogen
Since 2021, Schaeffler has added its own hydrogen unit to its service offer. Togetherwith the wind power sector, this works on new, integrated solutions that supportthe achievement of Schaeffler’s sustainability targets. Among other developments, anelectrolyzer for the production of green hydrogen is scheduled to start operation at the Schweinfurt plant.
Stacks, the key components of these electrolyzers, form part of the Schaeffler productportfolio. The Schaeffler K-Series Hydron PowerStack will have an application rangeof 1 to 1000 kilowatts. It will be designed and produced at Schaeffler sites in Europe, according to the highest quality standards. Electrolyzers can also be installed locally asmodular systems. This makes it possible, for example, to link them with individual windturbines.
Sector News
Large construction site for the energy transition: RWE modernises two wind farms and increases power generation
Ground frost, gusts of wind, cold – the RWE team braved the adverse conditions. Over the next few weeks, a total of around 100 employees and experts from RWE and its partner companies will be working on two wind farms to dismantle 17 older wind turbines and replace them with 11 new, more powerful ones. By repowering the wind farms in this way, RWE can significantly increase electricity production despite using fewer turbines. This is due to the larger rotor blades being able to capture more wind and produce green electricity even when the wind is weak. At the Lesse and Barbecke sites, the company will increase capacity from 30.6 to 61.8 megawatts (MW).
Katja Wünschel, CEO RWE Renewables Europe & Australia: “43,500 is the number of the day. Once operational, the wind farms will be able to supply the equivalent of 43,500 households with green electricity. Electricity production at both sites will more than triple. Repowering is therefore making an important contribution to the success of the energy transition. But it is not only the climate that benefits, since we voluntarily pay an RWE climate bonus of 0.2 cents per kilowatt hour produced to the local communities. The town of Salzgitter and the municipalities of Lengede, Burgdorf and Söhlde can look forward to a total annual income of up to €280,000, which will be distributed among the municipalities.”
RWE opts for established wind sites in Lesse and Barbecke
The local conditions make the area suitable for wind power, with sufficient distance from the nearest villages and good wind conditions. In Lesse, RWE will replace eleven turbines of the oldest generation (total capacity 19.8 MW) with eight modern turbines with a total capacity of 44.7 MW.
In Barbecke, RWE will replace six existing turbines (total capacity 10.8 MW) with three turbines with an installed capacity of 5.7 MW each (total capacity 17.1 MW). The team has started to set up the construction site and carry out initial road works.
Any repowering project is a logistical challenge. In parallel with the new construction, the old turbines need to remain connected to the grid for as long as possible in order to continue generating green electricity.
Jens Meyer, Project manager at RWE: “We really have our hands full. While we have already laid the first foundation with a diameter of more than 26 metres for the new wind farm in Lesse, we were able to start dismantling the old plant at the same time. We are doing this in the most environmentally-friendly and resource-efficient way possible. We are leaving areas that are no longer required in such a way that they can be used without restriction after dismantling. We also reuse some of the gravel removed from roads and crane pads in the new wind farm.”
How communities benefit from wind power
RWE operates around 90 onshore wind farms in its home market. Involving citizens and local authorities in renewable energy projects is a key element in driving forward the energy transition. It promotes local acceptance. In Germany, the company gives all municipalities with an RWE wind farm a share of the profits. As the RWE climate bonus is paid per kilowatt hour of electricity generated, communities where high-capacity plants are based benefit the most. This creates an additional incentive to replace older plants with modern ones. In Lesse and Barbecke, electricity production will more than triple after repowering. Municipalities can expect to receive up to €280,000 per year of wind farm operation, up from up to €80,000. The additional income can be used, for example, to financially support local facilities such as day-care centres for children, schools and fire brigades. RWE plans to commission all new plants this coming winter.
Sector News
The EU built a record 17 GW of new wind energy in 2023 – wind now 19% of electricity production
The EU built 17 GW of new wind energy in 2023, slightly up on 2022 – and more than ever in a single year in fact. But it’s not enough to reach the EU’s 2030 targets. The EU should be building 30 GW of new wind every year between now and 2030. The actions set out in the EU Wind Power Package and European Wind Charter will help increase the annual build-out – national implementation is key. Wind was 19% of all electricity produced in Europe’s last year.
According to WindEurope data, the EU built 17 GW of new wind farms in 2023: 14 GW onshore; 3 GW offshore. These numbers are slightly up on 2022 and are the most the EU has ever built in a single year. But it’s well below the 30 GW a year that the EU needs to build to meet its new 2030 climate and energy security targets.
Germany built the most new wind capacity followed by the Netherlands and Sweden. The Netherlands built the most new offshore wind, including the 1.5 GW “Hollandse Kust Zuid” – for now the world’s largest wind farm.
The IEA estimates that Europe will build 23 GW a year of new wind over 2024-28. The actions set out in the EU Wind Power Package should deliver a significant increase in the annual build-out – and strengthen Europe’s wind energy supply chain. National implementation of the actions is key.
To that end the commitment to deliver the Wind Power Package that 26 EU Energy Ministers signed before Christmas in the European Wind Charter was key. Crucial actions include the further simplification of permitting, improvements in the design of the auctions to build new wind farms and public financial support for wind turbine manufacturing and key infrastructure.
Wind was 19% of the electricity produced in the EU last year. Hydro was 13%, solar 8% and biomass 3%. Renewables in total amounted to 44% of electricity produced.
The amount of electricity produced from 1 GW of wind continued to grow. The “capacity factor” of new onshore wind farms now ranges from 30-48%, and new offshore wind is consistently 50%. The capacity factor measures how much output you get from a unit of capacity – it varies between different renewable technologies.
Sector News
A Race to the Top China 2023: China’s quest for energy security drives wind and solar development
China is on track to double its utility-scale solar and wind power capacity and shatter the central government’s ambitious 2030 target of 1,200 gigawatts (GW) five years ahead of schedule, if all prospective projects are successfully built and commissioned, according to a new report from Global Energy Monitor (GEM).
China on track to exceed 2030 wind & solar target
With 757 GW of already operating wind and solar, and an additional 750 GW of prospective wind and solar, the majority of which expected to come online by 2025, the central government’s 2030 target is expected to be met 5 years ahead of schedule.
The Global Solar and Wind Power Trackers identify prospective projects that have been announced or are in the pre-construction and construction phases totalling approximately 379 GW of large utility-scale solar and 371 GW of wind capacity, which is roughly equal to China’s current installed operating capacity.
Nearly all of this prospective capacity is part of the government’s 14th Five-Year Plan (2021-2025) and enough to increase the global wind fleet by nearly half and large utility-scale solar installations by over 85%. This amount of prospective solar capacity is triple that of the United States, and accompanied by China’s significant share of approximately one-fifth of the global prospective wind capacity.
The Global Solar and Wind Power Trackers also show:
. China’s operating large utility-scale solar capacity has reached 228 GW – more than the rest of the world combined.
. China’s combined onshore and offshore wind capacity has doubled from what it was in 2017 and now surpasses 310 GW.
. Operating offshore wind capacity has reached 31.4 GW, and accounts for approximately 10% of China’s total wind capacity and exceeds the operating offshore capacity of all of Europe
“This new data provides unrivaled granularity about China’s jaw-dropping surge in solar and wind capacity. As we closely monitor the implementation of prospective projects, this detailed information becomes indispensable in navigating the country’s energy landscape.” Dorothy Mei, Project Manager at Global Energy Monitor
“China is making strides, but with coal still holding sway as the dominant power source, the country needs bolder advancements in energy storage and green technologies for a secure energy future.” Martin Weil, Researcher at Global Energy Monitor
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